U.S. patent number 5,547,006 [Application Number 08/058,162] was granted by the patent office on 1996-08-20 for roll-up cellular shades.
This patent grant is currently assigned to Hunter Douglas Inc.. Invention is credited to Raymond N. Auger.
United States Patent |
5,547,006 |
Auger |
August 20, 1996 |
**Please see images for:
( Certificate of Correction ) ** |
Roll-up cellular shades
Abstract
A window shade comprising a base sheet-like material, such as a
fabric, (1) which hangs vertically from a roller and to which is
attached, by parallel narrow attachment means at intervals, a
second sheet-like material of a decorative character (3) which is
longer between its attachments (2) to the first material (1). If
there is sufficiently excess decorative material (3) between lines
of attachment (2), it folds twice between lines of attachment (2)
when such a shade is rolled up. When the shade unrolls, the
decorative material (3) flexes out from the base material (1)
because of its greater length and forms an air-filled cell.
Vertically arranged strips of these cells (18) may be formed on a
single base sheet, with each strip unique in various ways to obtain
a decorative effect. The shades may also be made of strips of
material running the width of the shade. Decorative material which
does not crease or fold tightly may be attached to the face of
flexible material on a cell-by-cell basis. Variations in the
dimensions of groups of cells can cause them to create decorative
patterns of different types when they are viewed collectively.
Inventors: |
Auger; Raymond N. (Aspen,
CO) |
Assignee: |
Hunter Douglas Inc. (Upper
Saddle River, NJ)
|
Family
ID: |
22015084 |
Appl.
No.: |
08/058,162 |
Filed: |
May 4, 1993 |
Current U.S.
Class: |
160/84.01;
160/121.1; 160/238 |
Current CPC
Class: |
B29C
65/08 (20130101); B29C 66/344 (20130101); B29C
65/7847 (20130101); B29C 66/437 (20130101); D06J
1/12 (20130101); E06B 9/266 (20130101); B29C
66/836 (20130101); D06H 5/00 (20130101); E06B
9/40 (20130101); B29C 66/729 (20130101); B29C
65/524 (20130101); B29C 66/1122 (20130101); E06B
9/262 (20130101); E06B 2009/2441 (20130101); E06B
2009/2622 (20130101); D10B 2503/02 (20130101); B29L
2031/719 (20130101); Y10T 156/1003 (20150115); B29C
66/71 (20130101); E06B 2009/2627 (20130101); D10B
2503/03 (20130101); B29C 66/8322 (20130101); Y10T
156/1015 (20150115); B29C 66/71 (20130101); B29K
2067/00 (20130101) |
Current International
Class: |
D06J
1/12 (20060101); D06J 1/00 (20060101); D06H
5/00 (20060101); E06B 9/26 (20060101); E06B
9/266 (20060101); E06B 9/24 (20060101); E06B
9/262 (20060101); E06B 9/40 (20060101); B29C
65/52 (20060101); E06B 009/06 () |
Field of
Search: |
;160/84.1D,84.1C,84.1R,238,87,89,121.1,107 ;156/204 ;428/188 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Johnson; Blair M.
Attorney, Agent or Firm: Polumbus; Gary M. Holland &
Hart LLP
Claims
What I claim is:
1. A window shade comprising the combination of a roller and a
first sheet secured to said roller and adapted to hang vertically
from the roller in a substantially planar orientation, said roller
having a predetermined circumference, a second sheet secured to the
first sheet by narrow attachments along spaced parallel horizontal
lines of attachment, the length of the second sheet between said
attachments being greater than the length of the first sheet
between the attachments such that when rolled on said roller, both
sheets lie against each other but when unrolled, air spaces are
created between the two sheets and the attachments, the distance
between said attachments, when less than the circumference of said
roller, being other than a whole number divisor of the
circumference of said roller.
2. A window shade comprising the combination of a roller and a
first sheet secured to said roller and adapted to hang vertically
from the roller in a substantially planar orientation, said roller
having a predetermined circumference, a second sheet secured to the
first sheet by narrow attachments along spaced parallel horizontal
lines of attachment, the length of the second sheet between said
attachments being greater than the length of the first sheet
between the attachments such that when rolled on said roller, both
sheets lie against each other but when unrolled, air spaces are
created between the two sheets and the attachments, the distance
between said attachments, when greater than the circumference of
said roller, being other than a whole number multiple of the
circumference of said roller.
3. A window shade as in claims 1 or 2 where the means of attachment
is an adhesive.
4. A window shade as in claims 1 or 2 where the means of attachment
is heat-sealing.
5. A window shade as in claims 1 or 2 where the means of attachment
is sewing.
6. A window shade as in claims 1 or 2 where the shade is rolled up
with the second sheet outermost on the roll.
7. A window shade as in claim 1 or 2 where the shade is rolled up
with the first sheet outermost on the roll.
8. A window shade as in claims 1 or 2 where the second sheet is
composed of strips which are oriented vertically and attached
adjacent to each other to the first sheet but not to each
other.
9. A window shade as in claims 1 or 2 where the second sheet is
used as a base on which to secure a decorative material which does
not fold, covering only the visible parts of the second sheet.
10. A window shade as in claims 1 or 2 where the second sheet has
one or more creases which is/are flattened when the shade is rolled
up.
11. A window shade as in claims 1 or 2 where neither of the two
folds is adjacent to the attachment line.
12. A window shade as in claims 1 or 2 wherein said first and
second sheets comprise strips of sheet material oriented in the
direction of the width of the shade, these strips being attached to
each other along said lines of attachment so that the entire shade
is composed of such strips.
13. A window shade as in claims 1 or 2 where one or more additional
sheets are attached to the second sheet at second lines of
attachment, each replicating the shape of the sheet to which it is
attached, the second lines of attachment being located at the
approximate center of the cells of sheet.
14. A window shade as in claims 1 or 2 where the length of said
second sheet between attachment lines is varied within a shade to
create a decorative pattern.
Description
BACKGROUND--FIELD OF THE INVENTION
This invention relates to window coverings, specifically those with
a roll-up cellular structure.
BACKGROUND--PRIOR ART
Window shades composed of multiple layers of fabric arranged to
create pockets of still air in their structure are commonly
described as cellular shades. Among the better-known of these is
described by Thomas P. Hopper in U.S. Pat. No. 4,194,550 of Mar.
25, 1980, which is a continuation-in-part of U.S. Pat. No.
4,039,019, of Jan. 26, 1976.
Hopper's widely-publicized invention had as its central function
the creation of a highly-insulating shade. However, for various
reasons, it did not become commercially successful. On the other
hand, Max Rasmussen, in U.S. Pat. No. 4,019,554, of Apr. 26, 1977,
described a "Thermally insulating curtain, especially for
greenhouses" which has become commercially very successful, not so
much for its utilitarian thermal characteristics as for its
appearance. While his shade can be, in theory, rolled up, its
design clearly intends it to be raised by accordion folding its
fabric. Rolling such a shade would create folds in places not shown
by his drawings.
Cellular shade designs to follow, such as Anderson's U.S. Pat. No.
4,677,013 of Jun. 30, 1987, Colson's U.S. Pat. No. 5,158,632 of
Oct. 27, 1992, and his U.S. Pat. No. 5,129,440 of Jul. 14, 1992,
show cellular shades that fold up. Folding shades pulled up by
cords are in the general category of Roman shades. Some inventors
have used rollers to wrap of the cords of Roman shades to obtain
the benefits of roller operation of a folding device. H. ShuKat et
al, in U.S. Pat. No. 3,487,875, of Jan. 6, 1970, is one example of
this approach.
While the insulating capability of cellular shades is highly
desirable, their appearance is a clearly the most important factor
in their sale. In this regard, Hopper's shade offered little, while
Rasmussen's shade offered an effect which proved highly desirable
to the public.
OBJECTS AND ADVANTAGES
It is an object of the presently described invention to create
cellular shades which can be rolled up rather than folded up, and
to give such shades a variety of visual effects by varying
construction parameters. There are some unique advantages to
rolling-up rather than folding-up shades. First, they are easier to
motorize, as they are simply wrapped around a motorized tube.
Second, the cord systems used to rotate rollers are widely,
although not universally, viewed as easier to operate than the
cord-lock or cord-cleat systems of folding shades. The operation of
spring rollers is also very familiar to many people.
A second object of the invention is the formation of cells using as
few seams and as little fabric as possible.
A third object of the invention is the creation of cells using
vertical strips of fabric for the room-facing surface, with the
possibility of unique cell patterns for each strip.
Another object of the invention is a cellular shade which can be
given a wide variety of cell shapes, while being manufactured by
one machine, simply by the variation of two cell dimensions.
Another object of the invention is the creation of an insulating
shade which can be inexpensively manufactured.
Another object of the invention is the creation of a cellular shade
which can be fabricated from large sheets of fabric or from narrow
strips run vertically or horizontally.
SUMMARY OF THE INVENTION
Throughout this description of my invention the word fabric shall
be used interchangeably with any type of flexible sheet material
such as plastic, plastic-laminated fabric, films or foils.
This invention utilizes a base fabric to which is secured a second
fabric, which is room-facing and of a decorative color. The
decorative fabric is secured horizontally at intervals to the base
fabric and is greater in length than the mounting fabric between
intervals. When such a combination is rolled up on a cylindrical
shape such as a roller, if there is sufficient excess decorative
fabric in each interval, it will be creased in two places in each
interval by the action of being rolled up. The relative location of
one of the creases changes as the total diameter of the rolled-up
fabric increases, causing each cell to have slightly unique
proportions, differing from all others on a given shade, even
though the lengths of fabric which compose them are the same.
Air-filled cells are created in the space between the base fabric
and the decorative fabric when the shade is unrolled. By varying
either or both the dimensions of the intervals and the amount of
room-facing fabric between intervals, a wide variety of visual
effects can be obtained. In addition, the method of manufacture may
permit the two variables which determine the size and shape of the
cells to be altered in the course of the assembly of one shade.
Another unique capability of the roll-up cellular shade is that the
face fabric may be applied in vertical strips, with each strip
given a unique cellular structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an edge view elevation of the cellular shade, showing its
relationship to its roller.
FIG. 2 is an edge view elevation view of the cellular shade with
cells too thin to produce fabric folding when rolled up.
FIG. 3 is a variation of FIG. 1 to the extent that a decorative
crease has been added.
FIG. 4 Is a side view of a few cells showing an alternate location
for the folds.
FIG. 5 is a schematic representation of a machine able to make the
shade shown in FIG. 1.
FIG. 6 is a frontal view of a shade made of vertical strips of
cells, with the cells of adjacent strips offset.
FIG. 7 is a side view of two layers of cells, one atop the other,
showing a broken out part of the top portion of a shade.
FIG. 8 is a side view of a few cells with a thick decorative
material secured to the exposed surface of one cell.
FIG. 9 is a side view of cells having a free hanging fabric
overlaid in front of the cells.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an edge view elevation of a typical shade made
according to the present invention. The base material, 1, would
normally face a window. To it is attached, 2, by adhesive, sewing
or any suitable means, a decorative material, 3. This pair of
materials, which may be fabrics or films, the term fabrics being
used herein to apply to both, is rolled up on a roller, 4, at which
time the folds 5 and 6 are made, permitting the decorative fabric,
3, to be rolled up tightly. Because the decorative fabric 3, when
rolled up, is always at a greater radius from the roller than the
base fabric 1, presuming the material is rolled so that the
decorative fabric is always external to the base fabric, then the
amount of decorative fabric between the fold 5 and the upper
attachment, 2, requires that the decorative fabric 3 expand outward
from the base fabric 1 when the shade is unrolled, creating an open
cell, 7. The curvature set in the fabric by being rolled up also
assists this process.
If the amount of decorative fabric in each interval is exactly the
same as required for both fabrics to roll up without stress to
either, then, when the fabrics are unrolled, a small air pocket, 7,
will be created between the two fabrics, illustrated by FIG. 2. As
the effective roller diameter grows with accumulating fabric on the
roller, this pocket becomes thinner, becoming both thermally and
decoratively inconsequential. However, if the room-facing fabric is
made slightly larger than results in a perfect accommodation to
being rolled up, resulting in a slight increase in effective roller
diameter, the cells so created will be noticeable for a limited
range of shade lengths which may satisfy some shade buyers. These
unfolded cells, that is, cells so thin that there is no folding of
the decorative fabric when they are rolled up, have some value in
stiffening a shade fabric across its width and in giving it modest
surface waviness.
FIG. 2 also illustrates a method of manufacture commonplace in
pleated folding cellular shades, the assemby of the shade through
the use of strips of fabric running across the width of the shade.
In my invention this technique can be employed for both fabrics of
the shade, as shown in FIG. 2, or for just the room-facing fabric.
The attraction of this technique is that permits the construction
of shades of any width. Its disadvantage is that two additional
bonds, 8 and 9, are required per cell. This strip assembly method
can be used for the configuration in FIG. 1, 3, 4, 7 and 8, to be
discussed.
Should a shade of the type shown in FIG. 1 be rolled up
"backwards", so that the decorative fabric faces the roller, the
cells will be much flatter. In some cases, a flatter cell may be
viewed as desirable, consequently, "reverse" rolling is a variant
of the invention.
In the manufacture of the shade according to the teachings herein,
the two critical dimensions are the length of the decorative fabric
3, between attachments, 2, and the length of the base fabric
between these lines. By varying these two dimensions, the cells, 7,
can be fat with the decorative fabric 3 highly rounded for each
cell, or the cells can be nearly flat, with only a slight curvature
for the decorative fabric 3.
It is possible to add decorative creases to the decorative fabric,
3. FIG. 3 shows such a crease, 10. It is also possible to relocate
the creases 5 and 6 of FIG. 1 to some other point on the decorative
fabric, as shown in FIG. 4. Both of the last described techniques
have the effect of giving the shade the appearance of a pleated
shaded, one normally folded up, whereas without the use of either
technique, the rounded surface of the cells provides an effect
quite different from that of pleated shades, dominated by the sharp
lines of each fold.
FIG. 5 is a schematic representation of a method of manufacture.
Roll of fabric 11 is the base fabric, and roll of fabric 12 the
decorative fabric. The two rollers 13 and 14 represent fabric
motion measuring devices, which control the intermittent feed
movements of the two rolls of fabric. Rollers 15 are idlers, while
the structure 16, represented as a nozzle, moves down the length of
fabric applying adhesive. In the case where the fabric on roll 12
consists of strips, the adhesive 17 would be laid down
intermittently to correspond to the cell pattern desired on
different strips. The movement, shown by arrows, of roller 18, is
for the purpose of pressing the two fabrics together wherever there
is a line of adhesive. Vacuum nozzle 19 pulls any slack fabric
between it and the roll 12 away from the base fabric to create a
cell prior to the movement of roller 18. As the assembled shade is
rolled up on roller 19, a pressure roller 20, forms the folds.
The action of the adhesive applicator, 16, is represented in highly
simplified form, as those familiar with the art will understand
that thermal or air-drying actions may be required to obtain proper
adhesive characteristics prior to bonding the fabrics. Also
understood by those familiar with the art is that a control
computer, not shown, will be required to coordinate the various
actions of the assembly machine, and that roller 16 will require
torque control to properly roll the fabric up.
The use of sewing or heat sealing rather than adhesives to bond the
fabrics together would require replacement of the rollers 12 and 14
with a sewing machine head which would traverse the width of the
fabric, or a heat sealing apparatus using any of the principles
employed by such devices.
The modifications of the machine need to obtain the displaced folds
seen in FIG. 4 should be apparent to anyone skilled in the art.
Because the folds are formed as the fabric rolls up on roller 19,
it is at that point that the displacement mechanism would be most
conveniently applied.
FIG. 6 is a frontal view of a shade made of vertical strips of
decorative fabric with the individual cells, 21, formed in each
strip offset a half cell from each other. While the drawing shows
cells of identical size, they may be of variable size, just as
strips of cells may be of different widths. Designs may be created
by the collective appearance of the cells. For example, in a large
shade made of strips of cells, those cells in the center of the
shade can be composed of flatter cells than the rest of the shade,
creating the image of a circle in the center of the shade. This
image would result from the difference in appearance of flatter
cells in contrast with fatter cells. Other images, such as squares,
diagonal stripes, or flowers are also attainable in this way.
The shade in FIG. 6 may use an open mesh for the window-facing
fabric, in which case it can be used for privacy in warm weather
while still permitting air flow through it.
It is also understood that when a shade is made of vertical strips
of cells, that a fabric change may occur at any cell by bonding a
different fabric to the strip at that point, creating a change of
color in a vertical direction.
FIG. 7 shows the cellular structure of FIG. 1 with a second layer
of cells, 22, similar to the first layer, attached to it to improve
its insulating value. Additional layers may be added in a similar
manner, with the attachment lines, 23, for the new layer in the
middle of the mounted cell in each case.
In this side view, which shows only a few cells at the top of a
shade, it may be presumed that the second layer of cells, 22, runs
the full width of the shade, or is composed of strips of the type
seen in FIG. 6.
FIG. 8 shows that a decorative material, 24, such as leather or
other material which is thick when folded or does not crease
easily, can be bonded to the unfolded (uncreased) face of a cell,
covering its visible surface. Because the limited extent to which
this surface is required to flex between free-hanging and roll-up,
the laminated material might be quite stiff, and outside of the
category of fabrics or films: for example, a wood veneer.
Cells may be located on both sides of a base fabric, so that the
cellular shape is presented towards the window as well as inside.
When this is the case, however, these out-facing cells will be more
flattened than interior cells of identical dimensions, as they will
be rolled up facing the roller.
The ends of the cells may be sealed closed to permit them to slide
in narrow tracks to improve the edge-seal of the shades in window
frames.
FIG. 9 shows a free-hanging fabric, 25, attached to the roller in
front of the cells, and at its bottom attached, 26, to the base
fabric, 1. Air will then be trapped between this fabric and the
cells, greatly improving the insulating ability of the shades. This
free-hanging fabric may also be of a semi-transparent material
creating an aesthetic effect in front of the cells of the shade,
and need not, for thermal reasons, be attached to the bottom of the
cellular shade, but may then have its own hem bar.
The thickness of the fabrics used for shades determines effective
roller diameter. However, in the case of the present invention, the
fold lines have two extra layers of fabric for a short distance.
Were the distance between the fold lines or the attachments to
exactly equal the effective circumference of the rolled up fabric
which increases with each additional wrap of fabrics, it would be
the case that all of the fold lines would fall atop each other,
making the fabric roll eccentric in diameter. This would also be
true for whole number multiples or devisors of the circumference.
Because the effective circumference of the roller with fabric
thereon changes with each of its revolutions, were all the cells
the same height (is the distance between attachments 2), it might
be the case that only three or four fold lines would fall
immediately on top of each other. However, as it is desirable to
avoid this effect. The way to prevent it is to prevent any cell
height, when it is less than its roll circumference (that is, the
effective circumference of the roller when it is added) from being
a whole number divisor of the effective roll circumference. When
cell height is larger than its roll circumference, its height, when
divisible by a whole number, should not equal the effective roll
circumference.
* * * * *